Method and apparatus for forming fine fibers



Aug. 5, 1952 E, R, POWELL 2,605,503

METHOD AND APPARATUS FOR'FORMINGFINE FIBERS Filed July 28, ,1950

INVENT 5ba/AJP@ P 6Min.

ATTORNEY Patented Aug. 5, 1952 METHOD AND APPARATUS Foa FoR-MING FINE Fresas Edward R. Powell, North. Plainfield, N. J., as-

signor `to Johns-Manville 'Coi-poration, New York, N. Y., a corporation of New York Application July 28, 1950, Seriallm 17 6,282 1`7 Claims. (C1. 18-,-2.'5)

The instant invention relates to a method of and apparatus for. producing fine fibers of glass and similar thermoplastic or meltable materials and is an improvement upon my formerapplication, S. lN. 118,815, filed September 30, 1949, of which it constitutes a continuation in part as to Vall common subject matter. It .will be appreciated that in this application, as in my said prior application, the'term .qglass is used in a generic sense to include glass compositions, synthetic low alkali glasses, natural glasses, mineral Wool compositions, and othermeltable materials.

vIn myprior application I have disclosed an apparatus and method ofdrawing ifine iibersvfrom thermoplastic materials of the type mentioned, the operationsinvolving the formation of a glass layer on thesurface ofla rotating body, and vthe contact with they layer by a plurality of VVprotuberances or points, preferably supported on an adjacent rotating body, whereby fibers are drawn from the surface oi" the layer by the protuberances upon continued rotation of the bodies. -The fibers thus initiated are drawn out into longer fibers by the application of forces applied transversely of the lengths ofthe bers while they are still attached to the layer of material and to the protuberances. The instant.Y invention has for its principal object theprovison of an imi of such methovdand apparatus involving the feed-` ing of the rawv material in particulate or powdered form, and the melting ,and depositing yof the par-v ticulate raw material on the surface of the body by the action'of a -melting'blast A further object of the invention is the provision of such My invention will be moreY fully understood and further objects and advantages thereof will become apparent when reference is made to the more detailed description of the invention which is to follow and to the accompanying drawings in which:v f

Fig. l isa longitudinal sectional view of an apparatus'embodying the invention, the view being taken on the line Al--P'I of Fig, 2; and

Fig. 2 is a transverse sectional view of the apparatus of Fig. 1, taken on the line 2--2 of Fig. l. v

Referring now to the drawings, the apparatus includes a rotor or body I0 mounted on a shaft l2 for rotation in the direction indicated by the arrow. Rotor I0 is of a construction to permit heating from room temperature to 18009 F.A without strain or eccentricity and to Vbe mechanically stable'and run true at elevated temperatures. Suitably .forthis purpose it includes a tire I made of a 'heat-resistant metal, connected to a hub iB by spokes. I8, 'the intervals between theA spokes being.l filled withl a, high temperature insulating. material. 29. If. desired, the tire can also be made of 'a suitable ceramic material.

A second.rotorv 22 is mounted on a shaft 2li lyingin parallelism with shaft I2. Rotors lil and apparatusl and method infwhichthe blast profi jects the material onto-thefsurface of the body at a point remote ,from the fiber drawing operation to permit conditioningofl the glass layer beforeiiber drawing.

AV Suu further object ofthe nvenuonfisfthe vprovision of an apparatus providing'an enclosed structure for the rotating bodies, the enclosing structure housing the melting burner and having drain openings for excess molten material.

22 are .inalignment andportions of their peripheral ysur'facesli'e in adjacent, parallel but non- .co'ntactingrelationship The peripheral surface of rotor il!) ispreferablysmooth, while that of rotor 22 isprovided with amultiplieity of pro- `imberances,A specifically pins'. or projectionsl,

suitably equally spaced at relatively close intervals over the peripheralsurface of the rotor. For example, the protuberances may be placed from 64 to 400 to the square inch. Rotor 22,

'except -for the` protuberances, is of similar construction to, but .suitably of somewhatsmaller diameter than, rotor Illv and is .mounted for rotation in the direction indicatedby the arrow, that is., in a direction opposite to rotor Hl. The rotors are driven byany suitable means at the same peripheral speeds, the drive being diagrammaticall'y illustrated at 23.

Rotors t@ andv22 areY enclosed, or substantially enclosed, by a housing l3,0 havingan extension 32 in the lower corneradjacent rotor l0. The housing 4is cutawayatrthe-bottDm and part way up the side walls, as indicated at 34, to provide room for the ber.. drawing and removal apparatus later to be described. The Yhousing may consist of a4 steel shell -36 lined with refractory. material of a characterto Vresist excessive erosion under .the temperatures involved. The housing is of a width to closely embrace the rotors, as illustrated particularly in'Fig. 2, and is of such length and height that the refractory lining is relatively close to the peripheries of the rotors, except at the corners and vparticularly at extension 32. Suitably vthe housing rand refractory lining are made in sectional form to permit their mounting about the rotors.

Burners 40 are mounted in apertures in the upper corners at the opposite Vends of the casing. Each of the burners is positioned to direct its flame along the refractory walls of the housing whereby the rotors and the air spaces between the walls and the rotors are principally heated by radiation from the refractory walls. The burners, which may be of conventional type, are connected by lines 42 to a suitable supply (not shown) of a fuel, such as a mixture of gas and air. The burners serve as means to condition a layer of raw material carried by rotor I6 for the fiber drawing operation, and also tormaintain the wheels at their optimum temperatures.

Mounted in extension l32 isa raw material melting and projecting device, indicated generally at 44. This device -consists of a plurality of, suitably two, burners 46 positioned to direct converging flamesagainst the adjacent peripheral surface of rotor l0. Burners 46 are connected by a supply line 48 .to any suitable source of fuel, such as a mixture of gas and air under such pressure that a high velocity blast is set up. The raw fiber-forming material in particulate form is delivered tothe naming blast issuing from burners 46. To this end a supply means for the particulate matter, such as hopper 50 having a valve for adjusting .the rate of flow from the hopper,

is mounted adjacent casing 3,0, the hopper being connected by feed conduit52 to a nozzle 54 having its outlet located between burners 46. Preferably a portion of the gaseous fuel from supply line 48 is by-passed to the feed line 52 to issue from nozzle 54 with theparticulate material. For this purposea connectingtube 56 may be provided between the fuel supply line48 and the feed line 52.

Extension 32 extends downwardly and rearwardlyas illustrated, from themain portion of the housing 30. rOne or. more drain openings 58 are providedat'the low point of theextension to permit any excess,k molten material to ow from the 'housing'.; One or more similar drain openings 60 may also be 'provided' at the other end of the h-ousing adjacent rotor 22 to permit the removal of any molten material which may be carried around bythe pointsf26 and deposited in the housing.,

Inthe operationof the apparatus described above and in carrying'out the method of the instant invention, glass of a suitable composition, whichA may beganyofjthose available for fiber drawing, xis suppliedin ground or particulate form to hopper 50.` The rawnmaterial is relatively nely1grou'nd vto have a particle size of 60 mesh to dust or- 1D0-200 zmesh. 'The material is fed to nozzle 54 and discharged therefrom, the feeding and discharge ofthe particulate matter being caused partiallylbygravity, and partially by the suction action ofthe blasts issuing from burners 46,l as 'well as byl'thepressurized gases entering- 'toY form a layer.

of the device. The particles are substantially immediately melted by the ame and projected as molten particles in relatively individualized, discrete relationship onto the surface of rotor I6 Thislayen is conditioned by burners A40 which directtheir amesf along the Wall of the casing, as explained above, to heat the refractory surfaces of the walls whereby the latter radiate heat to the glass layer. The conditioning is carried out at a temperature which will vary depending upon the particular glass or other material used, to maintain the glass at a molten but viscousstate as it reaches the fiber drawing operation. For example, commercial plate glass should be at a temperature of l750 F. to 1850 F. at this stage. The layer is carried by the rotor I0 to the bight between it and rotor 22 at Which point the protuberances or points 26 contact or dip into the glass layer on rotor I0. As the surfaces of the rotors move apart on continued rotation, each of the protuberances 26 which has dipped into or., been contacted by the glass layer draws a fiber from the layer whereby a multiplicity of parallelbersextend between the lprotuberances andthe layer, the fibers being elongated as the surfaces of therotors continue to separate.

The temperatures maintained within the casingare such that the protuberances areabove'th'e melting point of the glass and, hence, they do not tend to accumulate glass on successive rotation of the rotors, ,an requilibrium point being reached at which the amount, of glass on the protuberances is substantially constant. t Also, it has Vbeen determined that thetempe'rature of the rotor carrying the protuberances should be kept above, say,

20-30o above that of the other rotor.

The parallel fibers formed between the rotors I0 and 22 are carried' into a position where they arelpicke'd up by means which apply force transverselyof the ber lengths. This means or apparatus for vrpicking up and drawing out and length- Vening the fibersmay take different forms. For example, Vas illustrated, it may be substantially that shown and described in my said prior application,jS`.jN. 118,815, filed September 30, 1949. This `apparatus consists of a disc 62 mounted for rotation in the direction indicated by the arrow, the disc being positioned to have a downturning arc of its peripheral surface intercept the fibers yformed between the rotors. The periphery of disc 62carries a continuous.' series of pins or other projections 66 adapted to hook the fibers and carry them downwardly on rotation of the disc. Opposite the stretching disc is a pusher wheel 64 mounted for rotation in a direction opposite to that of the stretching disc, as indicated by the arrow, and at preferably the same, or slightly lower .peripheral speed.y The pusher wheel intercepts the fibers which are beyond the path of movement of the stretching disc 'and carries them into position to be picked up by pins66. The shafts of the ydisc and pusher wheel may be driven by any suitable mechanismv (not shown).

1 Gaseous jets 68 directed downwardly adjacent the periphery-of the disc and substantially at the point where the projections 66 point approximately downwardly, remove the fibers from the projections and further draw them out. These noz,-

Vzles are connected by a line 10 to a supply of any suitable gas under pressure, such as compressed air or superheated,V steam. lt will be appreciated that, in lieu of this device for elongating and removing the fibers drawn between'rotors l0 and 22, other suitable apparatus may be employed,

'the invention of the'instant application being directed tothe apparatus and-method-for' forming and conditioning the layerofber formingr material on the rotorl0, and for initially drawing the fibers between the rotors I0 and 22.

The drawn bers vmay be collected in any suitable way, for example, on a conveyor l2 located below the ber forming equipment,

The instant apparatus and method, described above, provide for uniform distribution of the material 'on the rotor `Illin the form of a 'layerfof Athe required thickness and at the desired temperature. As will be readily recognized, the thickness of the layer may be predetermined by proper feed ofthe particulate matter and by adjustment of the speed of rotation of the rotors. Inasmuch as no scraping or leveling loperation need be performed on the deposited glass, the glass need not be at the undesirably high temperatures necessary to fluidify it for such scraping or leveling operations. The'application of the material to the rotor at a point remote from the drawing operation permits the conditioning-of the glass to the specific range of viscosity for most-efcient operation. Any molten material which may tend to gather in the housing, either as a result of splattering of the material in the blast or otherwise, is drained from the area of operation through the drain opening 58 and similarly, molten material which may be carried from the zone of ber formation by protuberances 26 and the drip therefrom, may escape through drain opening 60.

Having thus described my invention in rather full detail, it will be appreciated that these details need not be strictly adhered to and that various changes and modifications may suggest ,themselves to one skilled in the art, ally falling within the scope of the invention as deiined by the subjoined claims.

What I claim is:

l. A method of making fibers comprising discharging molten particles of ber forming material onto the surface of a body to form a layer, contacting said layer with an element, and moving said element relatively away from said layer to draw a ber therefrom.

2. A method of making bers comprising depositing molten particles of ber forming material onto the surface of a body to form a layer,

carrying said layer on said body and conditioning the layer, contacting the layer with an element, and moving said element relatively away from the layer to draw a ber therefrom.

3. A method of making bers comprising melting particles of raw material, discharging the molten particles onto the surface of a body to form a substantially uniform layer, contacting said layer with an element, and moving said element away from said layer to draw a ber therefrom.

4. A method of making bers comprising melting particles of raw ber forming material in a flame, discharging the molten particles in relatively discrete relationship onto the surface of a body to form a layer, contacting said layer with an element, and moving said element relatively to said layer to draw Aa fiber therefrom.

5. A method of making fibers comprising melting particles of raw ber forming material in a ame, discharging the molten particles in relatively discrete relationship onto the surface of a body to form a layer, contacting said layer with an element, maintaining said element at a temperature above said body, and moving said V`6 element relatively to said .layer to ldraw fa ber therefrom. 1 v l 6. Amethodiof :making-bers comprising conveying particles of 'raw ber`formingmaterial together with a gaseous fuel to a name, melting the particles in the flame, discharging the molten particles in relatively discrete relationship'onto the surface of Ia body to form a layerconveying said layer on said body 'while conditioning the layer, contacting `said layer with a `plurality of elements, and 'moving'said elements'irelatively to said layer to draw bers therefrom.

7.y A method of making bers comprising melting particles of raw ber forming material, projecting the V'molten Aparticles onto rthe surface of a moving body to form a substantially uniform layer thereon, contacting said layer with a plurality of elements, moving said elements relatively away from'said layer to drawberstherefrom,'and` applyingforce 'to the bers, saidv force moving transversely of the fibers while the bers are attached to the layer and elements.

8. In an apparatus forproducing bers, a body for carrying alayer of ber formingmaterial, means movable relatively away from said body for contactingnjsaid layerv and drawing a ber therefrom, 'and means for' f discharging molten particles of .berffonning material onto said bodytoformsaidlayer 'thereonv i 9. In an apparatus for producing bers, a'body for ca'rrying'alaye'r ofl ber forming material, means movable relatively yaway from said body for contacting said* layer and drawing bers therefrom, means for discharging' particles of ber forming raw material, means for melting the particles, and means forjpro-jecting the molten particles onto the body tofor-m the layer.

10. In an apparatus Lfor producing bers, a body for `carry-ing a layer `of ber forming material, means movable relatively 'away from said body for contacting said layer and drawing fibers therefrom, means for supplying particles of ber forming raw material, a melting blast directed toward said body, and means for feeding the particles to the blast whereby the particles are melted and projected onto said body to form the layer thereon by said blast. y

11. In an apparatus for producing bers, a rotatable body for carrying a layer of ber forming material, means movable relatively away from said body for contacting said layer and drawing bers therefrom, means for supplying particles of ber forming raw material, a melting blast directed toward said body at a point remote from the ber drawing operation, means for feeding the particles to the blast whereby the particles are melted therein and projected onto said body to form the layer thereon, and means for conditioning said layer on the vbody before it reaches the ber drawing operation.

12. In an apparatus for producing fibers, a body for carrying a layer of ber'forming material, means movable relatively away fro-m said body for contacting said layer `and forming a ber therefrom, a hopper for particles of raw ber forming material, means for setting up a particle melting blast directed toward said body, and a feed pipe leading from the hopper to the blast.

13. In an apparatus for producing bers, a body for carrying a layer of ber forming material, means movable relatively away from said body for contacting said layer and forming bers therefrom, a hopper for particles of raw ber forming material, means for setting up a Aparticle melting blast directed toward said body,

a feed pipe leading from the hopper to the'blast, and means for supplying fuel to said feed pipe for intermixtu're with said particles.

`14.'In anapparatus for producing fibers, a. rotor having a peripheral surface for receiving a layer of molten material, a second'rotor, elements projecting from said second rotor to contact said layer on said first rotor at a bight therebetweenmeans mounting said rotors for rotation with said elements moving into and out of contact with said layer of draw fibersl therefrom, al housing partially enclosing the rotors, means for setting up a flaming blast in said housing directed toward said rst rotor at a point remote from the bight between the rotors, means for feeding particles of fiber forming raw material to said blast whereby said first rotor receives a layer of molten material, and heating means for conditioning the layer as it is carried by the first rotor to said bight.

15. In an apparatus for producing fibers, rotor having a peripheral surface for receiving a layer of molten material, a second rotor, elements projecting from saidsecond rotor to contact said layeron said first lrotor at a bight therebetween, means mounting said rotors for rotation with said elements moving into and lout of contact with said layer to draw fibers therefrom, a casing partially' enclosing the rotors,

said casingl having an extensionat Va corner thereof adjacent the rst rotor, `a .burner mounted within said extension .for directing a flaming blast toward said rst rotorl at a point removed from the bight betwentherotors, and meansfor feeding particulate fiber formingraw material to said blast.4 y

V16. In an Vapparatus for producing fibers, a rotor having a peripheral surface for receiving a layer of molten material, a second rotor,-elements projecting from said second rotor to contact said layer on said rst rotor at a bight therebetween, means mounting said rotors for rotation with said elements moving into and out of contact with said layer to draw fibers therefrom, a housing partially enclosing the rotors, said housing having an extension at a corner thereof adjacent the first rotor, a burner mounted within said extension for directing a flaming blast toward said first rotor at a point removed from the bight between the rotors, means for feeding particulate fiber forming raw material to said blast, anda drain opening in said extension to permit excess molten material to drain from the housing.

17. In an apparatus for producing fibers, a rotor having a, peripheral surface for receiving a layer of molten material, a second rotor, elements projecting from said second rotor to contact said layer at a bight betwen the rotors, a housing partially enclosing the rotors and having lower corners defining the low spots of the housing, a burner mounted within the housing adjacent one of said corners to direct a particle melting blast toward said first rotor, means for supplying raw material to said blast, and drain openings in said housing at said corners to permit excess molten material to drain from the housing.

EDWARD R. POWELL.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Nam-e Date 1,617,166 Schoop Feb. 8, 1927 1,756,381 Pahl Apr. 29, 1930 2,385,358 Hanson Sept. 25, 1945 

